阅读说明：本技术 一种陶瓷类产品的制造方法 (Method for manufacturing ceramic products ) 是由 杨小康 刘轶 张龙江 王敏 于 2021-08-30 设计创作，主要内容包括：本申请涉及一种陶瓷类产品的制造方法,包括：将陶瓷粉末材料、增韧剂、增塑剂和分散增强剂按预设比例进行机械混合得到预制粉末；对混合好的预制粉末进行干燥处理；将干燥后的预制粉末利用3DP打印机进行陶瓷模壳打印成型；对成型的陶瓷型壳固化后进行清粉处理；将清理完毕的陶瓷型壳放入无机粘结剂中进行浸渗处理；对浸渗后的陶瓷型壳进行干燥处理；当陶瓷型壳上的无机粘结剂完全干燥固化后,放入烧结炉进行烧结。本方案能够解决目前的陶瓷材料较难应用于3D打印行业的问题。(The present application relates to a method for manufacturing a ceramic product, comprising: mechanically mixing a ceramic powder material, a toughening agent, a plasticizer and a dispersion reinforcing agent according to a preset proportion to obtain prefabricated powder; drying the mixed prefabricated powder; printing and molding the ceramic mould shell by using a 3DP printer on the dried prefabricated powder; carrying out powder cleaning treatment on the formed ceramic shell after solidification; putting the cleaned ceramic shell into an inorganic binder for infiltration treatment; drying the ceramic shell after infiltration; and after the inorganic binder on the ceramic shell is completely dried and solidified, putting the ceramic shell into a sintering furnace for sintering. The problem that the present ceramic material is difficult to be applied to the 3D printing industry can be solved.)

1. A method for manufacturing a ceramic product, comprising:

mechanically mixing a ceramic powder material, a toughening agent, a plasticizer and a dispersion reinforcing agent according to a preset proportion to obtain prefabricated powder;

drying the mixed prefabricated powder;

printing and molding the ceramic mould shell by using a 3DP printer on the dried prefabricated powder;

carrying out powder cleaning treatment on the formed ceramic shell after solidification;

putting the cleaned ceramic shell into an inorganic binder for infiltration treatment;

drying the ceramic shell after infiltration;

and after the inorganic binder on the ceramic shell is completely dried and solidified, putting the ceramic shell into a sintering furnace for sintering.

2. The manufacturing method according to claim 1, wherein the mechanically mixing the ceramic powder material, the toughening agent, the plasticizer and the dispersion strengthening agent according to a preset ratio to obtain the pre-formed powder specifically comprises: taking the following materials in proportion: 81 to 98 percent of ceramic powder material, 1 to 6 percent of toughening agent, 0.2 to 3 percent of plasticizer and 2 to 4 percent of dispersion reinforcing agent are mechanically mixed to obtain prefabricated powder.

3. The method as claimed in claim 2, wherein the toughening agent comprises one or more of carbon fiber of 500-2000 mesh, nano silica, nano clay, and glass fiber of 80-5000 mesh.

4. The method according to claim 2, wherein the plasticizer is 300 to 600 mesh zinc oxide powder or zinc stearate.

5. The production method according to claim 2, wherein the dispersion-enhancing agent comprises one or more of carbon black, fine silica powder, nano titanium dioxide, and nano silica having a particle size of 300 to 600 mesh.

6. The method of claim 1, wherein the inorganic binder comprises one or more of a silicate, a phosphate, and a sulfate.

7. The manufacturing method according to claim 1, wherein the impregnating the cleaned ceramic shell in the inorganic binder specifically comprises:

when the wall thickness of the cleaned ceramic shell is more than 50mm, putting the ceramic shell into an inorganic binder to infiltrate for 5-40 min;

and when the wall thickness of the cleaned ceramic shell is more than 1m, performing brushing and penetration, and repeatedly brushing for 5-10 times by using a fiber brush to ensure that the inorganic binder is completely penetrated.

8. The manufacturing method according to claim 1, wherein the step of printing and molding the dried pre-formed powder into a ceramic form by using a 3DP printer specifically comprises: and the 3DP printer performs ceramic mould shell printing forming on the dried prefabricated powder by preset printing parameters, wherein the preset printing parameters comprise a layer thickness of 0.10-0.3mm and a resolution of 0.01-0.04mm, and the addition of the resin is ensured to be 1.0-12.0%.

9. The manufacturing method according to claim 1, wherein the drying process of the impregnated ceramic shell mold specifically includes: and (3) putting the impregnated ceramic shell into an air drying oven for drying treatment, wherein the drying temperature is set to be 80-150 ℃, and the drying time is set to be 1-5 h.

10. The method as claimed in claim 1, wherein the ceramic powder material is one or more of 100-450 mesh zircon powder, mullite powder, quartzite powder, white corundum powder, 70-450 mesh silica sand, ceramsite sand and thermal sand.

Technical Field

The invention relates to the technical field of additive manufacturing, in particular to a manufacturing method of a ceramic product.

Background

The ceramic material has the characteristics of high hardness, high strength, good chemical stability, high temperature resistance and the like, and is widely applied to the fields of machinery, electronics, semiconductors, aerospace and the like. However, the ceramic material is difficult to form and process due to the characteristics of high hardness and high strength, and the traditional manufacturing method of the ceramic shell for casting has the defects of complex process, more materials, poorer comprehensive performance, large production field, low production efficiency, lower shell strength, long manufacturing period, low automation degree, slow product heat dissipation, large internal defects, incapability of large-scale production and the like, so that the wide application of the ceramic shell is limited.

The existing three-dimensional printing mainly takes ceramsite sand, silica sand, thermally-regenerated sand, gypsum powder and the like as powder materials, and the used binder mainly takes furan resin, phenolic resin, urethane resin and other organic resins as main materials, but products formed by adopting the powder materials and the resin cannot be applied to the field of high-temperature roasted ceramic materials; and the types of the current binders for ceramic material printing are few, and the inorganic salt binders have the problems of long curing period, easy blockage of a printing head in the printing process, deformation, cracking, low density and the like in the sintering process of a formed product. Therefore, it is a technical problem to be solved in the art to develop a 3D printing process scheme applied to ceramic materials.

Disclosure of Invention

Therefore, it is necessary to provide a method for manufacturing ceramic products, which aims at solving the problem that the existing ceramic materials are difficult to be applied to the 3D printing industry.

In order to solve the problems, the invention adopts the following technical scheme:

the embodiment of the invention discloses a method for manufacturing a ceramic product, which comprises the following steps:

mechanically mixing a ceramic powder material, a toughening agent, a plasticizer and a dispersion reinforcing agent according to a preset proportion to obtain prefabricated powder;

drying the mixed prefabricated powder;

printing and molding the ceramic mould shell by using a 3DP printer on the dried prefabricated powder;

carrying out powder cleaning treatment on the formed ceramic shell after solidification;

putting the cleaned ceramic shell into an inorganic binder for infiltration treatment;

drying the ceramic shell after infiltration;

and after the inorganic binder on the ceramic shell is completely dried and solidified, putting the ceramic shell into a sintering furnace for sintering.

In one embodiment, the mechanically mixing the ceramic powder material, the toughening agent, the plasticizer and the dispersion strengthening agent according to a preset ratio to obtain the pre-formed powder specifically includes: taking the following materials in proportion: 81 to 98 percent of ceramic powder material, 1 to 6 percent of toughening agent, 0.2 to 3 percent of plasticizer and 2 to 4 percent of dispersion reinforcing agent are mechanically mixed to obtain prefabricated powder.

In one embodiment, the toughening agent comprises one or more of carbon fiber with 500-2000 meshes, nano-silica, nano-clay and glass fiber with 80-5000 meshes.

In one embodiment, the plasticizer is 300-600 mesh zinc oxide powder or zinc stearate.

In one embodiment, the dispersion reinforcing agent comprises one or more of carbon black, silicon powder, nano titanium dioxide and nano silicon dioxide with 300-600 meshes.

In one embodiment, the inorganic binder comprises one or more of a silicate, a phosphate, and a sulfate.

In one embodiment, the step of putting the cleaned ceramic shell into an inorganic binder for infiltration includes:

when the wall thickness of the cleaned ceramic shell is more than 50mm, putting the ceramic shell into an inorganic binder to infiltrate for 5-40 min;

when the wall thickness of the cleaned ceramic shell is more than 1m, a brushing and permeating method is carried out, a fiber brush is adopted to brush for 5-10 times repeatedly, and the inorganic binder is ensured to permeate completely;

in one embodiment, the step of printing and molding the ceramic mold shell with a 3DP printer on the dried preformed powder specifically includes: and the 3DP printer performs ceramic mould shell printing forming on the dried prefabricated powder by preset printing parameters, wherein the preset printing parameters comprise a layer thickness of 0.10-0.3mm and a resolution of 0.01-0.04mm, and the addition of the resin is ensured to be 1.0-12.0%.

In one embodiment, the drying process of the ceramic shell after infiltration specifically includes: and (3) putting the impregnated ceramic shell into an air drying oven for drying treatment, wherein the drying temperature is set to be 80-150 ℃, and the drying time is set to be 1-5 h.

In one embodiment, the ceramic powder material is one or more of 100-450-mesh zircon powder, mullite powder, quartz powder, white corundum powder, 70-450-mesh silica sand, ceramsite sand and thermal sand.

The technical scheme adopted by the invention can achieve the following beneficial effects:

in the manufacturing method of the ceramic product disclosed by the embodiment of the invention, the specific 3D printing process scheme is adopted, the process requirement of high-temperature roasting of ceramic is met, the ceramic product can be directly printed in a 3D printing mode, and the production processes of opening a die to make slurry and the like are reduced. Compared with the existing manufacturing method of ceramic products, the manufacturing method of the ceramic products can be used for manufacturing the ceramic products in a 3D printing mode, so that the production cost can be saved, the production period of the ceramic products can be shortened, and the working efficiency can be improved.

Drawings

Is free of

Detailed Description

The present invention may be embodied in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

It will be understood that when an element is referred to as being "disposed on" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. As used herein, the terms "vertical," "horizontal," "left," "right," "top," "bottom," "top," and the like are for illustrative purposes only and do not represent the only embodiments.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

The embodiment of the invention discloses a manufacturing method of a ceramic product, which comprises the following steps:

s100, mechanically mixing the ceramic powder material, the toughening agent, the plasticizer and the dispersion reinforcing agent according to a preset proportion to obtain prefabricated powder.

S200, drying the mixed prefabricated powder; specifically, the mixed pre-prepared powder is dried in a drying device at 90-120 ℃ for 1-3h to facilitate the subsequent printing process.

And S300, printing and molding the dried prefabricated powder by using a 3DP printer.

S400, performing powder cleaning treatment on the formed ceramic shell after solidification, so that all adhered powder except the ceramic shell can be clear, and the appearance quality of the formed ceramic shell is ensured.

And S500, putting the cleaned ceramic shell into an inorganic binder for infiltration treatment, wherein the infiltration time of the ceramic shell can be increased according to the increase of the wall thickness of the ceramic shell.

S600, drying the ceramic shell after infiltration.

And S700, when the inorganic binder on the ceramic shell is completely dried and solidified, putting the ceramic shell into a sintering furnace for sintering. Specifically, after the inorganic binder is completely dried and cured, the ceramic shell is placed into a sintering furnace and sintered for 2-5 hours at the temperature of 1000-1700 ℃, and the heating rate can be 5-20 ℃/min, so that the printing quality of the ceramic shell is ensured.

As can be seen from the above, in the manufacturing method of the ceramic product disclosed in the embodiment of the invention, the specific 3D printing process scheme is adopted, so that the process requirement of high-temperature ceramic roasting is met, the ceramic product can be directly printed in a 3D printing mode, and the production processes of mold opening and slurry making are reduced. Compared with the existing manufacturing method of ceramic products, the manufacturing method of the ceramic products can be used for manufacturing the ceramic products in a 3D printing mode, so that the production cost can be saved, the production period of the ceramic products can be shortened, and the working efficiency can be improved.

In the embodiment disclosed in the present invention, step S100 may specifically include: the following materials can be taken: 81 to 98 percent of ceramic powder material, 1 to 6 percent of toughening agent, 0.2 to 3 percent of plasticizer and 2 to 4 percent of dispersion reinforcing agent are mechanically mixed to obtain prefabricated powder. The ceramic powder can be used for preventing sand mould from collapsing and has better mechanical property when the furan resin is used as a binder; the glaze powder in the ceramic powder enables the roasted product to be more compact, the surface to be smoother and the defects to be less, expands the roasting temperature range and realizes degreasing and ceramization of the ceramic powder product; the high refractive index oxide makes the fired product more glossy.

The manufacturing method disclosed by the embodiment of the invention can be suitable for the production of ceramic products of the molding and sintering processes of precision casting ceramic shell (core), high-temperature alloy casting ceramic shell (core), titanium alloy casting ceramic shell (core) and special ceramic parts.

Further, the toughening agent can comprise one or more of 500-2000 mesh carbon fiber, nano-silica, nano-clay and 80-5000 mesh glass fiber.

Furthermore, the plasticizer can be zinc oxide powder or zinc stearate with 300-600 meshes.

Further, the dispersion reinforcing agent can comprise one or more of carbon black, silicon powder, nano titanium dioxide and nano silicon dioxide with 300-600 meshes.

In the disclosed embodiments, the inorganic binder may include one or more of a silicate, a phosphate, and a sulfate.

Further, step S500 may specifically include:

when the wall thickness of the cleaned ceramic shell is more than 50mm, putting the ceramic shell into an inorganic binder to infiltrate for 5-40 min;

and when the wall thickness of the cleaned ceramic shell is more than 1m, performing brushing and penetration, and repeatedly brushing for 5-10 times by using a fiber brush to ensure that the inorganic binder is completely penetrated. In this case, the impregnation time for the ceramic shell is increased according to the increase in the wall thickness of the ceramic shell, thereby securing the impregnation effect of the ceramic shell.

In the embodiment of the present disclosure, step S300 may specifically include: the 3DP printer can print and form the ceramic mould shell on the dried prefabricated powder by preset printing parameters, wherein the preset printing parameters comprise the layer thickness of 0.10-0.3mm and the resolution of 0.01-0.04mm, and the addition of the resin is ensured to be 1.0-12.0%. By the method, the quality of the printed ceramic products can be better ensured.

In this embodiment of the present invention, step S600 may specifically include: and (3) putting the impregnated ceramic shell into an air-blast drying oven for drying treatment, wherein the drying temperature is set to be 80-150 ℃ and the drying time is set to be 1-5h in the drying process. The method is convenient to operate, and the drying effect of the ceramic shell is good. Of course, the ceramic shell after impregnation may be dried by other methods, which is not limited in the embodiment of the present invention.

In one embodiment, the ceramic powder material is one or more of 100-450-mesh zircon powder, mullite powder, quartz powder, white corundum powder, 70-450-mesh silica sand, ceramsite sand and thermal sand.

The following is a description of the method for making the ceramic product disclosed by the invention by specific examples:

in a specific scheme, 95.7 percent of zirconia powder material, 2 percent of glass fiber serving as a toughening agent, 0.3 percent of zinc oxide powder serving as a plasticizer and 2 percent of silicon micropowder serving as a dispersion reinforcing agent are sequentially added into a tank type mixer, the rotating speed is 250r/min, and the mixture is ball-milled for 1 hour;

drying the mixed prefabricated powder at 120 ℃ for 3 h;

mixing the dried powder with 0.2% furan resin curing agent, wherein the layer thickness is 0.24mm, the resolution is 0.03mm, and printing a ceramic product to obtain a printed product with the tensile strength of 1.44 MPa;

carrying out die drawing and powder cleaning after the formed ceramic part is solidified for 2 hours;

putting the cleaned ceramic parts into a silicate inorganic binder to infiltrate for 10 min;

putting the impregnated ceramic part into a forced air drying oven, setting the drying temperature at 120 ℃, and drying for 3 hours until the tensile strength is 2.57 MPa;

and after the inorganic binder is completely dried and solidified, placing the inorganic binder into a sintering furnace to be sintered for 2 hours at the temperature of 1400 ℃. The heating rate is 15 ℃/min, and the tensile strength of the sintered product is 5.81 MPa.

In another specific scheme, 94.5 percent of alumina powder material, 3 percent of glass fiber serving as a toughening agent, 0.5 percent of zinc oxide powder serving as a plasticizer and 2 percent of nano titanium dioxide serving as a dispersion reinforcing agent are sequentially added into a tank mixer, the rotating speed is 300r/min, and the mixture is ball-milled for 1 hour;

drying the mixed prefabricated powder at 120 ℃ for 3 h;

mixing the dried powder with 0.26% furan resin curing agent, wherein the layer thickness is 0.2mm, the resolution is 0.02mm, and printing a ceramic product to obtain a printed product with the tensile strength of 1.25 MPa;

carrying out die drawing and powder cleaning after the formed ceramic part is solidified for 2.5 hours;

putting the cleaned ceramic parts into a silicate inorganic binder to infiltrate for 15 min;

putting the impregnated ceramic part into a forced air drying oven, setting the drying temperature at 120 ℃, and drying for 3 hours until the tensile strength is 2.21 MPa;

and after the inorganic binder is completely dried and solidified, putting the inorganic binder into a sintering furnace for sintering for 3 hours at 1200 ℃. The heating rate is 20 ℃/min, and the tensile strength of the sintered product is 5.28 MPa.

The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.